Recovery Act: Oxy-Combustion Technology Development For Industrial-Scale Boiler

Applications DE NT-0005290

•Armand Levasseur Alstom Power, Windsor, CT

NETL CO2 Capture Technology Conference

Pittsburgh, PA July 11, 2012

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

The Alstom Group: A Worldwide Leader in Power Generation

N°1 in services for electric utilities

N°1 in air quality control systems

N°1 in integrated power plants

Clean Power

Recent acquisition of solar and wind

N°1 in hydro power N°1 in conventional nuclear power island

CO2-Free & Renewables

Carbon Capture - Post Combustion - Oxy Combustion

12 CCS Pilots 5 Large Demo Projects

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Oxy-Combustion: Benefits and Issues

Source : Alstom analysis – 2011 – PC power plants with CCS – transport and storage included

35

45

55

65

75

85

2010 2015 2020 2025 2030 2035

Oxy

Post

Ref Power plant

€/ MWh net

+45%

• Cost competitive with other CCS, wind, solar, biomass, nuclear

• Reliable - main components only need to be adapted and scaled-up, plant operation demonstrated in large pilots

• Environmentally friendly - low emissions, no large chemical feedstocks or new emission sources

• Retrofit and “CCS Ready” Applications • Rapid scale-up to large commercial (1000

MWe) sizes & high efficiency steam cycles • Flexible operation and power production

options • High CO2 capture rates (>90%)

• Must use the entire boiler island for demonstration requiring substantial funding

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Large Pilot Plants

Demonstration

Full-Scale

2008

2017

Alstom Oxy-Combustion Technology Development Steps

Lab Scale

1998

<3 MWth

15- 30 MWth

150- 400 MWe

600-1100 MWe

Reference Design Studies

Modeling & Tool Dev.

2012

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Develop and validate an oxyfuel T-fired boiler system as part of commercially attractive CO2 capture solutions.

• Design and develop an oxyfuel firing system for T- fired boilers

• Evaluate the performance in pilot scale tests at 15 MWth testing - operation, combustion, heat transfer, pollutants, ash deposition and corrosion

• Evaluate and improve engineering and simulation tools for oxy-combustion by applying detailed test data obtained

• Develop design guidelines • Develop the design, performance and costs for a

demonstration-scale oxyfuel boiler and auxiliary systems. • Develop the design and costs for both industrial and

utility commercial-scale reference oxyfuel boilers

Oxy T-Fired Boiler Development Project Objectives

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

6

Oxy T-Fired Boiler Development Budget & Schedule

Total Budget: $21.5 M Project Team:

Alstom DOE –NETL ICCI NDIC Utilities

Project Start: Oct 2008 Duration: 5 Yrs

Utility Advisory Group Ameren ATCO Dominion Energy Great River Energy Luminant (TXU) LCRA and Austin Energy MidWest Generation NB Power OG&E Vattenfall

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Task 1 - Project Management 70% Completed

Task 2 - Bench Testing 40% Completed

Task 3 – Screening Evaluations 100% Completed

Task 4 - 15 MWth Testing 85% Completed4.1 Test Planning Done4.2 Test Preparations Done4.3 Facility Shakedown Done4.4 Campaign 1 Done4.5 Campaign 2 Done4.6 Campaign 3 Done4.7 Campaign 4 Done4.8 Campaign 5 Done4.9 Campaign 6 On-Going

Task 5 - Test Data Analysis 75% Completed

Task 6 – Model Simulations 65% Completed

Task 7 – Oxy Guidelines Milestone Completed 25% Completed

Task 8 - Oxy Boiler Demo Design Milestone Scheduled 55% Completed

Task 9 – Commercial Ref. Designs 65% Completed

Period 2 Period 3 Period 5Period 4Task Description

Period 1

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

15 MWth Oxyfuel Pilot Plant: Alstom Boiler Laboratories, Windsor, CT

15 MWth Boiler Simulation Facility Multi-burner, Tangentially-fired

Flexible operating conditions - air & oxy-firing, gas recycle configuration, oxygen injection, firing system design

Generation of detailed design and performance data -combustion, emissions, heat transfer, deposition, corrosion

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Accomplished • Process and CFD Screening Completed • Modifications For Oxy-Firing Completed • Campaign 1 Completed

Sept. 2009 – PRB subbituminous coal • Campaign 2 Completed

Feb. 2010 - Low S bituminous coal • Campaign 3 Completed • April 2010 - High S Illinois Bit coal • Campaign 4 Completed Oct.

2010 - North Dakota lignite • Campaign 5 Completed

Aug. 2011- Schwarze Pumpe lignite • Campaign 6 – Test 1 Completed

Dec. 2011 – Advanced Concepts On-Going

• Tools & Modeling Refinement and Validation • Design Guidelines • Reference & Demo designs

Oxy T-Fired Boiler Development Project Status

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Comparsion of 15 and 30 MWth Schwarze Pumpe Lignite Results

Established link between 15 and 30 MWth Test Programs

Tested over conditions overlapping both 30 MW and previous 15 MW tests

Lignite Staging Tests15 MWth BSF & 30 MWth Oxy PP

0.00

0.10

0.20

0.30

0.40

Windbox StoichiometryN

Ox

emis

sion

s (lb

/MM

BTU

)

30MWth Air30MWth Oxy15MWth Air15MWth Oxy

Similar NOx Behavior in Both Pilots

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Close-Coupled Recirculation System.

• Demonstrated Close-Coupled (High Temp) gas recycle for low S coal • Savings in downstream equipment CAPEX (SCR, gas-gas heater, ESP) and fan power – Overall economics evaluated in FY13 • Able to achieve 100% secondary gas recycle with single eductor and O2 motive gas (Replaces FD fan in oxy mode)

2nd Generation Boiler Concepts: Close-Couple FGR with Eductor

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

15 MWth Oxy-Combustion Pilot Plant: Detailed Mapping Data For CFD Validations

Air Oxy

Alstom 15MWth BSFND Lignite Long-Term Testing

Oxy

Air

oxyfired heat flux profile can be controlled to match air fired

2,7012,8002,8202,8162,8022,7502,7612,745

2,7392,7982,8252,7942,7742,7862,7922,737

2,6552,7072,7572,8222,8022,7942,7502,697

2,6972,7502,7072,6952,7012,7322,7102,696

20 30 40 50 60 70 80 90 100 110

30

40

50

60

70

80

90

30

40

50

60

70

80

90

Front

Probe Measurements - Gas Temperatures - Gas Composition - Heat Flux

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

20 25 30 35 40

OxyAir

30%

35%

40%

45%

50%

55%

60%

Heat Absorption

Global Oxygen Conc.

Furnace Waterwall Heat Flux – Can Be Control During Oxy-Firing

5

10

15

20

25

Furnace

Height

33% 24% 28%

VW Bituminous

Heat Flux

Global O2 Conc.

Ability to control heat flux magnitude with recycle rate

Reduced recycle rate shifts heat duty to furnace

Alstom 15MWth BSFND Lignite Long-Term Testing

Oxy

Air

Able to closely match air firing

heat flux

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

CFD Model Development Oxy-PC Boiler Model Refinement and Validation

• ANSY FLUENT code: Submodel improvements for radiation, soot, NOx

• Detail comparisons with 15 MW BSF tests, 30 MW OxPP, and 0.5 MW IFK oxy combustor

– refinement – validation

• Joint effort with ICSE at U of Utah

– Systematic evaluation of experimental data and simulations

– Uncertainty analysis – Large Eddy Simulations

15 MW BSF - Temperature Simulation & Measurements

0.5 MW IFK -Temperature Simulation & Measurements

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Dynamic Model Development Oxy-PC Boiler Island Model

Aspen Dynamics Platform • Detailed boiler model • Overall oxy capture plant

model Dynamic Simulation

• Assess transient response – Operating modes – Load changes – Failure behavior

• Design advanced controls

Oxy-Boiler Island GPU

Turbine Island

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Oxy Reference Plant and Demonstration Boiler Designs

• Application of test results and design tools

• Development of reference oxy- fired utility boiler design for future market – 900 MWe gross USC bit coal

• Development of oxy-fired boiler designs for demonstration opportunities – 400 MWe Dual Air/Oxy optimized design

• Optimization, detailed design, performance assessment and costing

Oxy T-Fired Boiler Designs

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Large Commercial Reference Boiler Design

Boiler Specifications • 900 MWe Gross • Supercritical, sliding pressure

with spiral wall evaporator • USC – 279/52 bar, 600/620 C • Direct pulverized coal firing,

Tilting-tangential firing system Design Fuel

• Range of Bituminous Coals

Operation • Optimized for Oxy • Base load operation • Min. Load 40%

Boiler Design Optimized for Overall

Plant Performance and Cost

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Oxy-firing Integrated Approach: For entire capture plant

• Numerous parameters impacting performance and cost – Integration is key (process, thermal, operation, arrangement)

• Globally optimize cost of electricity

• Balance trade-offs between main subsystems (performance and costs)

• Optimize pollutant removal

• Power plant operation and control

• Optimize arrangement and minimize footprint

An integrated approach minimizes the cost of electricity

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Demonstration Unit Design Boiler Specifications

• 400 MWe Gross • Supercritical, sliding pressure

with spiral wall evaporator • USC – 279/52 bar, 600/620 C • Direct pulverized coal firing,

Tilting-tangential firing system Design Fuel

• Range of Bituminous Coals

Operation • Dual 100% Air / 100% Oxy • Cycling load operation • Min. Load 25%

Low NOx T- Fired System With CCOFA & 2-Levels SOFA

SCR (with economizer & gas by-passes)

Ljungstrom gas-gas heater with special sealing to minimize leakage

O2 Injection before gas-gas heater & into windbox

Boiler Design Optimized for Overall Plant Performance and Cost

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

The White Rose CCS Project in the UK

Location: Drax Power Station, North Yorkshire, UK

ALSTOM DRAX

Project Promoters

NATIONAL GRID

Oxy-fuel Power Plant CO2 Transportation & Storage

BOC-Linde

Project: New 426 MWe Plant Ultra Supercritical Steam Entire Gas Stream Processed Pipeline Transport & Offshore Storage Applied for UK & EU Funding Pre-FEED Nearly Completed

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Concluding Remarks

• No technical barriers that would restrict the continued development and commercialization of oxy-combustion – Combustion performance, emissions, and thermal behavior

(temperature, heat flux intensity, heat flux profile) can be controlled to similar levels or better as air firing

– Oxy boiler design concepts to improve overall plant performance and cost are being investigated

• Detailed test data from this project and other Alstom R&D programs is being applied to – refine and validate design tools and design procedures – support overall oxy plant integration and optimization

efforts – develop and optimize designs for demonstration

opportunities and future commercial plants

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Acknowledgements and Disclaimer

Acknowledgement The work presented was supported by the US Department of Energy through the National Energy Technology Laboratories under Agreement DE NT-0005290. The guidance and direction of NETL Project Manager Tim Fout is acknowledged and appreciated. Disclaimer Parts of this presentation were prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

Information disclosed herein is furnished to the recipient solely for the use thereof as has been agreed upon with ALSTOM and all rights to such information are reserved by ALSTOM. The recipient of the information disclosed herein agrees, as a condition of its receipt of such information, that ALSTOM shall have no liability for any direct or indirect damages including special, punitive, incidental, or consequential damages caused by, or arising from, the recipient’s use or non-use of the information